Sponge dough process

Abstract

An improved process for producing baked products such as breads and rolls is provided which gives the products an extremely long shelf life and essential batch-to-batch uniformity. Moreover, the process is susceptible to a high degree of automation, thereby lowering costs. Broadly speaking, the process of the invention is an improvement over conventional sponge methods and involves initially setting the sponge fraction at a temperature of about 72°-80° F. and a pH of 5.2-5.6; the sponge is fermented for a period of about 11/2-21/2 hours in order to elevate the temperature and reduce the pH of the sponge. The sponge is then cooled to eliminate yeast activity, and is mixed with dough fraction components to yield a final dough. The final mixed dough is quiescently held and proofed in an intermediate proofer for 6-8 minutes. Final processing involves molding, baking, cooling and packaging. The process is also characterized by a complete absence of synthetic yeast foods in the sponge fraction.

I claim: 
     
       1. In a sponge dough process for preparing a final dough including the steps of preparing a yeast-containing sponge fraction and a dough fraction, initially setting the sponge fraction and allowing it to ferment, mixing the sponge and dough fractions to yield a final dough, and dividing and proofing the final dough, the improvement which comprises the steps of: preparing said sponge fraction such that the sponge fraction contains from about 40 to 60% by weight of the total flour content of the final dough, and initially setting said sponge fraction at a temperature of from about 72° to 80° F. and a pH of from about 5.2 to 5.6;   fermenting said initially set sponge fraction for a period of from about 11/2 to 21/2 hours and under conditions such that at the end of the fermentation period the sponge fraction has a temperature of from about 82° to 84° F. and a reduced pH as compared with the initial set pH;   reducing the temperature of the sponge fraction to a level of from about 40° to 45° F.;   mixing said dough fraction and said sponge fraction after the latter has been reduced in temperature to yield said final dough, and thereafter quiescently holding the final dough for a period of from about 15 to 30 minutes; and   subjecting the quiescently held final dough to an intermediate proofing step for a period of from about 6 to 8 minutes.   
     
     
       2. The sponge dough process of claim 1, said sponge fraction containing about 50% by weight of the total flour content of said final dough. 
     
     
       3. The sponge dough process of claim 1, said sponge fraction being free of synthetic yeast food. 
     
     
       4. The sponge dough process of claim 1, said initial setting temperature being from about 74° to 78° F. 
     
     
       5. The sponge dough process of claim 1, said initial setting pH being from about 5.4 to 5.6. 
     
     
       6. The sponge dough process of claim 1, said fermentation time being about 2 hours. 
     
     
       7. The sponge dough process of claim 1, the pH of said sponge fraction after said fermentation period being reduced at least about 1/10 pH unit as compared with said initial set pH. 
     
     
       8. The sponge dough process of claim 1, said quiescent holding period of said final dough being for a period of about 20 minutes.